Integrated Urea Sender Unit for Compact Conditioning Circuits
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Solution Overview
Problem
Existing urea conditioning circuits for vehicles are bulky and expensive due to the presence of brackets, dedicated wiring, and connection pipes, necessitating a more compact and economical solution.
Innovation Solution
A urea sender unit with an integrated electrovalve and reduced piping, featuring a heat exchange pipe and a compact design that includes a damper and sensor means, allowing direct signal processing and control without a vehicle control unit, and separate housings for the electrovalve and control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bracket, dedicated wiring, and connection pipes are used to install the electrovalve and connect the conditioning circuit, then the electrovalve can be properly installed and connected, but the space occupied increases and the cost increases
Solution Approach 1:
The electrovalve is integrated directly into the sender unit housing, merging previously separate components (electrovalve, sender unit, wiring harness, and mounting bracket) into a single compact assembly. This eliminates the need for external brackets, dedicated wiring, and connection pipes, thereby reducing the space occupied while maintaining reliable installation and connection.
2Reliability
If a bracket, dedicated wiring, and connection pipes are used to install the electrovalve and connect the conditioning circuit, then the electrovalve can be properly installed and connected, but the manufacturing cost increases
Solution Approach 1:
The electrovalve is integrated directly into the sender unit housing, merging previously separate components (electrovalve, sender unit, wiring harness, and mounting bracket) into a single compact assembly. This reduces the number of parts that need to be manufactured, stored, and assembled, thereby lowering manufacturing costs while ensuring reliable installation and connection.
Solution Approach 2:
The sender unit housing serves multiple functions: it houses the temperature sensor, provides the mounting structure for the electrovalve, contains the damping means, and provides fluidic connections. This multi-functionality reduces the need for separate components, lowering manufacturing complexity and cost while maintaining reliable connections.
3Ease of operation
If the electrovalve is installed on the vehicle frame with external wiring and pipes, then the conditioning circuit can be assembled, but the assembly is complex and maintenance is difficult
Solution Approach 1:
The electrovalve is integrated directly into the sender unit housing, merging previously separate components (electrovalve, sender unit, wiring harness, and mounting bracket) into a single compact assembly. This integration dramatically simplifies the assembly process by reducing the number of components and connections, making the conditioning circuit easier to assemble and maintain.
4Reliability
If external wiring and connection pipes are used for the electrovalve, then the electrovalve can be connected to the control unit, but the risk of mechanical damage increases
Solution Approach 1:
The electrovalve is integrated directly into the sender unit housing, eliminating external wiring and connection pipes that are susceptible to mechanical damage. The integrated design protects the electrical and fluidic connections from exposure to harsh external environments, reducing the risk of mechanical damage while maintaining reliable connections between the electrovalve and control unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a smaller, cost-effective urea conditioning circuit with reduced space requirements, easier maintenance, and improved vibration dampening, facilitating easier assembly and reducing the risk of mechanical damage.
Implementation Method 1
a heat exchange pipe (3), which is part of a urea conditionign circuit (100), which axially extends under the head (2)
Implementation Method 2
damping means (30) operatively interposed between the disc (4) and the electro valve (27) to allow dampening of vibration due to operation of the electro valve to the other elements of the sender unit (1)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Sender unit (1) for conveying a solution of urea into a vehicle, comprising an upper portion (2) configured to be inserted in an opening of a tank for the urea solution; the upper portion (2) defines a first and a second orifice (5, 6) adapted to be connected to an inlet pipe (11) and to an outlet pipe (12) forming part of a conditioning circuit (100); the sender unit (1) further comprises: - a heat exchange pipe (3) connected to the first and to the second orifice (5, 6) and adapted to be at least partially immersed in the urea solution, - sensor means for detecting a temperature of the urea solution, and - an electrical interface unit (23) connected to the sensor means, the electro valve (27) being a three-way two-position valve configured to provide a flow rate of urea solution in a range between 0 and 600 l/h with a pressure drop that varies between 0 and 300 mbar.